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Volkswagen VW Diesel Transporter T4 1990-2003 Haynes
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VW T4 Transporter Diesel 1990 - 2003 Haynes Owners Service & Repair Manual covers Transporter 'T4' variants with front-mounted diesel engines and front-wheel-drive.
* Diesel Engines Covered: 1.9 litre (1896cc) 4 Cylinder and 2.4 litre (2370cc) & 2.5 litre (2461cc) 5 Cylinder * DOES NOT cover petrol engine models, all-wheel-drive 'Syncro' models, interior features specific to Westfalia, Caravelle or Multivan, or specialist bodywork/camper conversions. * DOES NOT cover Transporter 'T5' range introduced July 2003. Contents: * Safety First! * Roadside repairs * Weekly checks * Routine maintenance and servicing * 4 - Cylinder engine in-vehicle repair procedures * 5 - Cylinder engine in-vehicle repair procedures * Engine removal and overhaul procedures * Cooling, heating and ventilation systems * Fuel and exhaust systems * Emission control systems * Starting and charging systems * Clutch * Manual transmission * Automatic transmission * Driveshafts * Braking system * Suspension and steering * Bodywork and fittings * Body electrical systems * Wiring diagrams * Reference |
The Volkswagen Transporter (T4), marketed in united states given that Volkswagen Eurovan, is a van generated by the German manufacturer Volkswagen Commercial Vehicles between 1990 and 2003, succeeding the Volkswagen means 2 (T3) and superseded because of the Volkswagen Transporter (T5).
Introduced in 1990, the T4 had been 1st Volkswagen van to own a front-mounted, water-cooled system. Prompted by the popularity of similar moves using their passenger automobiles, Volkswagen have toyed in late 1970s using concept of replacing their particular air-cooled, rear-engined T2 vans with a front-engined, water-cooled design. The reason why for deciding in 1980 to alternatively present a brand new rear-engined T3 were unclear. Thus, the development of a front-engined layout is delayed until the arrival of T4. After a run of almost 14 ages, T4 manufacturing ceased in 2003, rendering it 2nd only to the T1 for amount of manufacturing in its real estate market.
The main success of the T4 ended up being its flexibility. It had been available in numerous kinds and sizes as standard and formed the cornerstone of many specialist cars, from buses to campervans to ambulances.
Wheelbase
Two standard wheelbases had been available; "quick" (2920mm) and "long" (3320mm).
System sort
Van
Panel Van - with no microsoft windows behind the b-pillar; single row of seats
Kombi or Half-Panel - with extra house windows between the b and c-pillars; 2 rows of chairs
Caravelle or Multivan - with microsoft windows all-round; 3 rows of chairs (referred to as Eurovan in US)
Pickup
Solitary cab - predicated on a SWB chassis
Dual taxi - based on a LWB framework (aka Doka, from the German: Doppelkabine)
Roofs
Panel vans are available with two various roof levels; standard (1940mm) and high-top (2430mm). High-tops were only made regarding LWB chassis, although campervan conversion rates often have pop-top or (usually fibreglass) high-tops put into both SWB and LWB chassis.
Doors
Vans posses often one, roof-hinged "tailgate" or two "barn" doorways within back and both a single (passenger side) or twin (both edges) sliding doors.
Extended and short-nose
There was one major renovation to your T4, in 1996, when a re-shaped, much longer front end is launched. This is needed seriously to compliment the six-cylinder VR6 system into the T4's motor bay. Initially, best Caravelles and Multivans had been readily available utilizing the longer nostrils, because these had been the sole models readily available because of the VR6 system.
The commercial variations continued to be created using the smaller nostrils until 1999. However, campers as well as other specialist automobiles produced between 1994 and 1999 may have both the short and/or longer nose, based which model had been put due to the fact base car. Commensurate with the kind 2's naming convention, the quick and long-nose variations are informally referred to as T4a and T4b, correspondingly.
Four-wheel Drive (Syncro)
The T4 has also been readily available with a permanent 4WD program that makes use of a Viscous coupling product as a center differential to manage the circulation of torque into back axle. These designs are called "syncro" and are readily available using 2.4D, 2.5Tdi and 2.5 petrol motors on all body kinds and both wheelbases. Some syncro brands also provide a mechanically securing back differential. Considering that the back differential precludes the keeping the extra wheel inside usual room beneath the human anatomy, syncro vans either store it inside the body or on an external, hinged bracket.
Campervans
The T4 are an extremely preferred base for design a little to medium-sized camper and day-vans, both as self-build work as well as professional sales. Volkswagen by themselves in addition marketed campervan variations for the T4, produced by and named after their specialist, Westfalia-Werke.
Petrol engines
Design Engine ID signal Engine configuration Engine displacement DIN rated motive energy @ rpm Torque @ rpm ages
1.8 PD inline-4 SOHC 8v 1,781 cc (108.7 cu in) 67 PS (49 kW; 66 bhp) @ 4,000 140 N*m (103 lbf*ft) @ 2,200 1990--1992
2.0 AAC inline-4 SOHC 8v 1,968 cc (120.1 cu in) 84 PS (62 kW; 83 bhp) @ 4,300 159 N*m (117 lbf*ft) @ 2,200 1990--2003
2.5 AAF; ACU inline-5 SOHC 10v 2,461 cc (150.2 cu in) 112 PS (82 kW; 110 bhp) @ 4,500 190 N*m (140 lbf*ft) @ 2,200 1990--1997
2.5 AET; APL; AVT inline-5 SOHC 10v 2,461 cc (150.2 cu in) 115 PS (85 kW; 113 bhp) @ 4,500 200 N*m (148 lbf*ft) @ 2,200 1997--2003
2.8 VR6 AES VR6 DOHC 12v 2,792 cc (170.4 cu in) 140 PS (103 kW; 138 bhp) @ 4,500 240 N*m (177 lbf*ft) @ 3,000 1996--2000
2.8 V6 AMV, AXK VR6 DOHC 24v 2,792 cc (170.4 cu in) 204 PS (150 kW; 201 bhp) @ 6,200 245 N*m (181 lbf*ft) @ 2,500 2000--2003
Diesel machines
Indirect shot
Design motor ID signal system configuration Engine displacement DIN rated motive energy @ rpm Torque @ rpm ages
1.9 D 1X inline-4 SOHC 8v 1,896 cc (115.7 cu in) 61 PS (45 kW; 60 bhp) @ 3,700 127 N*m (94 lbf*ft) @ 1,700 1990--1995
1.9 TD ABL inline 4 SOHC 8v 1,896 cc (115.7 cu in) 68 PS (50 kW; 67 bhp) @ 3,700 140 N*m (103 lbf*ft) @ 2,000-3,000 1993--2003
2.4 D AJA inline-5 SOHC 10v 2,370 cc (144.6 cu in) 75 PS (55 kW; 74 bhp) @ 3,700 160 N*m (118 lbf*ft) @ 1,900-2,900 1997--2003
2.4 D AAB inline-5 SOHC 10v 2,370 cc (144.6 cu in) 78 PS (57 kW; 77 bhp) @ 3,700 164 N*m (121 lbf*ft) @ 1,800 1990--1998
Turbocharged Direct Injections
Model motor ID code Engine setup system displacement DIN rated motive energy @ rpm Torque @ rpm Compression Ratio ages
2.5 TDI AJT; AYY inline-5 SOHC 10v 2,461 cc (150.2 cu in) 88 PS (65 kW; 87 bhp) @ 3,700 195 N*m (144 lbf*ft) @ 2,000-2,600 19,5 1998--2003
2.5 TDI ACV; AUF; AYC; AXL inline-5 SOHC 10v 2,461 cc (150.2 cu in) 102 PS (75 kW; 101 bhp) @ 3,500 250 N*m (184 lbf*ft) @ 1,900-2,300 19,5 1995--2003
2.5 TDI AHY; AXG inline-5 SOHC 10v 2,461 cc (150.2 cu in) 151 PS (111 kW; 149 bhp) @ 4,000 295 N*m (218 lbf*ft) @ 1,900-3000 19,0 1998--2003
The Transporter T4 is shipped to united states from 1992 until 2003 underneath the moniker Eurovan.
In america, the quick wheelbase Eurovan 5-cylinder traveler systems (CL, GL, GLS, and MV) were only sold for design season 1993. Smaller than a typical US delivery van, but bigger than an American or Japanese passenger minivan, Volkswagen played up its dimensions using slogan, "EuroVan: there is nothing mini about any of it". VW just brought in all of them to your United States for example seasons because deals in the usa had been disappointing, but business continued in Canada and Mexico. VW reintroduced the Eurovan passenger brands in the US for design season 1999 with a VR6 motor as standard, and stopped it once more with globally T4s after 2003. The handbook transmission wasn't available in united states using VR6 system.
VW brought in the short wheelbase Eurovan 5-cylinder fuel motor traveler models (CL, GL, GLS, MV Weekender and Westfalia Camperised) to Canada from 1991 to 1996. The 77 hp 2,4L diesel engine was recommended in Canada between 1993 to 1996. The longer wheelbase version was also on offer in 1992 best as a 10 seaters CL or GL design trim. Combi and crewcab pick-up versions (marketed as Transporter) were additionally for sale in 1992. A panel version (long wb only) ended up being offered from 1993 to 1997.
The Eurovan Camper by Winnebago had been launched in the usa and Canada in 1995 with the five-cylinder system, and is upgraded into the VR6 when it comes to 1997-2003 systems. These were just on the extended 3,320 mm (131 in) wheelbase T4. These small pop music top camper vans are special in united states and now have created a cult appropriate.
Winnebago also built three smaller course C motorhomes because of the forward cab associated with the T4/Eurovan labeled as the Rialta, Vista, and Sunstar(Itasca labeled). The Rialta is available in 1995-1996 with all the five-cylinder engine, in 1997-2001 utilizing the AES type of the VR6, as well as in 2002-2005 using the AXK system. The Vista and Sunstar are only stated in 2002-2004, all with the AXK system.
Into the U.S., the designs are:
the seven-seat Eurovan CL,GL, and GLS
the Eurovan MV, where the second line of chairs face the trunk and are detachable, the next line converts into a sleep, a foldable table in traveler location, window treatments, and a fluorescent lamp above table.
the Eurovan MV Weekender, an MV plus a Westfalia transformation that adds a pop-top roof, a moment expense sleep, bug screens for side microsoft windows and back hatch, full collection of curtains, additional electric battery, fluorescent interior lighting and under chair thermoelectric cooler.
the Eurovan Camper, the lengthy wheelbase commercial van transformed by Winnebago Industries to incorporate a pop-top roofing, two two-person beds, seating for four (plus optional solitary or two-person center seating), a single cubic base refrigerator that operates on propane, DC, or AC, a propane furnace, a wardrobe, cupboards, sink with chilled water and a grey water container, a two-burner propane kitchen stove, two two-person dinette tables, coach electric battery, residence lights, plus the two forward container seats designed to swivel around to handle the dinette/kitchen room. The 2000 EVC are 17 foot long (5,189 mm.)
Introduced in 1990, the T4 had been 1st Volkswagen van to own a front-mounted, water-cooled system. Prompted by the popularity of similar moves using their passenger automobiles, Volkswagen have toyed in late 1970s using concept of replacing their particular air-cooled, rear-engined T2 vans with a front-engined, water-cooled design. The reason why for deciding in 1980 to alternatively present a brand new rear-engined T3 were unclear. Thus, the development of a front-engined layout is delayed until the arrival of T4. After a run of almost 14 ages, T4 manufacturing ceased in 2003, rendering it 2nd only to the T1 for amount of manufacturing in its real estate market.
The main success of the T4 ended up being its flexibility. It had been available in numerous kinds and sizes as standard and formed the cornerstone of many specialist cars, from buses to campervans to ambulances.
Wheelbase
Two standard wheelbases had been available; "quick" (2920mm) and "long" (3320mm).
System sort
Van
Panel Van - with no microsoft windows behind the b-pillar; single row of seats
Kombi or Half-Panel - with extra house windows between the b and c-pillars; 2 rows of chairs
Caravelle or Multivan - with microsoft windows all-round; 3 rows of chairs (referred to as Eurovan in US)
Pickup
Solitary cab - predicated on a SWB chassis
Dual taxi - based on a LWB framework (aka Doka, from the German: Doppelkabine)
Roofs
Panel vans are available with two various roof levels; standard (1940mm) and high-top (2430mm). High-tops were only made regarding LWB chassis, although campervan conversion rates often have pop-top or (usually fibreglass) high-tops put into both SWB and LWB chassis.
Doors
Vans posses often one, roof-hinged "tailgate" or two "barn" doorways within back and both a single (passenger side) or twin (both edges) sliding doors.
Extended and short-nose
There was one major renovation to your T4, in 1996, when a re-shaped, much longer front end is launched. This is needed seriously to compliment the six-cylinder VR6 system into the T4's motor bay. Initially, best Caravelles and Multivans had been readily available utilizing the longer nostrils, because these had been the sole models readily available because of the VR6 system.
The commercial variations continued to be created using the smaller nostrils until 1999. However, campers as well as other specialist automobiles produced between 1994 and 1999 may have both the short and/or longer nose, based which model had been put due to the fact base car. Commensurate with the kind 2's naming convention, the quick and long-nose variations are informally referred to as T4a and T4b, correspondingly.
Four-wheel Drive (Syncro)
The T4 has also been readily available with a permanent 4WD program that makes use of a Viscous coupling product as a center differential to manage the circulation of torque into back axle. These designs are called "syncro" and are readily available using 2.4D, 2.5Tdi and 2.5 petrol motors on all body kinds and both wheelbases. Some syncro brands also provide a mechanically securing back differential. Considering that the back differential precludes the keeping the extra wheel inside usual room beneath the human anatomy, syncro vans either store it inside the body or on an external, hinged bracket.
Campervans
The T4 are an extremely preferred base for design a little to medium-sized camper and day-vans, both as self-build work as well as professional sales. Volkswagen by themselves in addition marketed campervan variations for the T4, produced by and named after their specialist, Westfalia-Werke.
Petrol engines
Design Engine ID signal Engine configuration Engine displacement DIN rated motive energy @ rpm Torque @ rpm ages
1.8 PD inline-4 SOHC 8v 1,781 cc (108.7 cu in) 67 PS (49 kW; 66 bhp) @ 4,000 140 N*m (103 lbf*ft) @ 2,200 1990--1992
2.0 AAC inline-4 SOHC 8v 1,968 cc (120.1 cu in) 84 PS (62 kW; 83 bhp) @ 4,300 159 N*m (117 lbf*ft) @ 2,200 1990--2003
2.5 AAF; ACU inline-5 SOHC 10v 2,461 cc (150.2 cu in) 112 PS (82 kW; 110 bhp) @ 4,500 190 N*m (140 lbf*ft) @ 2,200 1990--1997
2.5 AET; APL; AVT inline-5 SOHC 10v 2,461 cc (150.2 cu in) 115 PS (85 kW; 113 bhp) @ 4,500 200 N*m (148 lbf*ft) @ 2,200 1997--2003
2.8 VR6 AES VR6 DOHC 12v 2,792 cc (170.4 cu in) 140 PS (103 kW; 138 bhp) @ 4,500 240 N*m (177 lbf*ft) @ 3,000 1996--2000
2.8 V6 AMV, AXK VR6 DOHC 24v 2,792 cc (170.4 cu in) 204 PS (150 kW; 201 bhp) @ 6,200 245 N*m (181 lbf*ft) @ 2,500 2000--2003
Diesel machines
Indirect shot
Design motor ID signal system configuration Engine displacement DIN rated motive energy @ rpm Torque @ rpm ages
1.9 D 1X inline-4 SOHC 8v 1,896 cc (115.7 cu in) 61 PS (45 kW; 60 bhp) @ 3,700 127 N*m (94 lbf*ft) @ 1,700 1990--1995
1.9 TD ABL inline 4 SOHC 8v 1,896 cc (115.7 cu in) 68 PS (50 kW; 67 bhp) @ 3,700 140 N*m (103 lbf*ft) @ 2,000-3,000 1993--2003
2.4 D AJA inline-5 SOHC 10v 2,370 cc (144.6 cu in) 75 PS (55 kW; 74 bhp) @ 3,700 160 N*m (118 lbf*ft) @ 1,900-2,900 1997--2003
2.4 D AAB inline-5 SOHC 10v 2,370 cc (144.6 cu in) 78 PS (57 kW; 77 bhp) @ 3,700 164 N*m (121 lbf*ft) @ 1,800 1990--1998
Turbocharged Direct Injections
Model motor ID code Engine setup system displacement DIN rated motive energy @ rpm Torque @ rpm Compression Ratio ages
2.5 TDI AJT; AYY inline-5 SOHC 10v 2,461 cc (150.2 cu in) 88 PS (65 kW; 87 bhp) @ 3,700 195 N*m (144 lbf*ft) @ 2,000-2,600 19,5 1998--2003
2.5 TDI ACV; AUF; AYC; AXL inline-5 SOHC 10v 2,461 cc (150.2 cu in) 102 PS (75 kW; 101 bhp) @ 3,500 250 N*m (184 lbf*ft) @ 1,900-2,300 19,5 1995--2003
2.5 TDI AHY; AXG inline-5 SOHC 10v 2,461 cc (150.2 cu in) 151 PS (111 kW; 149 bhp) @ 4,000 295 N*m (218 lbf*ft) @ 1,900-3000 19,0 1998--2003
The Transporter T4 is shipped to united states from 1992 until 2003 underneath the moniker Eurovan.
In america, the quick wheelbase Eurovan 5-cylinder traveler systems (CL, GL, GLS, and MV) were only sold for design season 1993. Smaller than a typical US delivery van, but bigger than an American or Japanese passenger minivan, Volkswagen played up its dimensions using slogan, "EuroVan: there is nothing mini about any of it". VW just brought in all of them to your United States for example seasons because deals in the usa had been disappointing, but business continued in Canada and Mexico. VW reintroduced the Eurovan passenger brands in the US for design season 1999 with a VR6 motor as standard, and stopped it once more with globally T4s after 2003. The handbook transmission wasn't available in united states using VR6 system.
VW brought in the short wheelbase Eurovan 5-cylinder fuel motor traveler models (CL, GL, GLS, MV Weekender and Westfalia Camperised) to Canada from 1991 to 1996. The 77 hp 2,4L diesel engine was recommended in Canada between 1993 to 1996. The longer wheelbase version was also on offer in 1992 best as a 10 seaters CL or GL design trim. Combi and crewcab pick-up versions (marketed as Transporter) were additionally for sale in 1992. A panel version (long wb only) ended up being offered from 1993 to 1997.
The Eurovan Camper by Winnebago had been launched in the usa and Canada in 1995 with the five-cylinder system, and is upgraded into the VR6 when it comes to 1997-2003 systems. These were just on the extended 3,320 mm (131 in) wheelbase T4. These small pop music top camper vans are special in united states and now have created a cult appropriate.
Winnebago also built three smaller course C motorhomes because of the forward cab associated with the T4/Eurovan labeled as the Rialta, Vista, and Sunstar(Itasca labeled). The Rialta is available in 1995-1996 with all the five-cylinder engine, in 1997-2001 utilizing the AES type of the VR6, as well as in 2002-2005 using the AXK system. The Vista and Sunstar are only stated in 2002-2004, all with the AXK system.
Into the U.S., the designs are:
the seven-seat Eurovan CL,GL, and GLS
the Eurovan MV, where the second line of chairs face the trunk and are detachable, the next line converts into a sleep, a foldable table in traveler location, window treatments, and a fluorescent lamp above table.
the Eurovan MV Weekender, an MV plus a Westfalia transformation that adds a pop-top roof, a moment expense sleep, bug screens for side microsoft windows and back hatch, full collection of curtains, additional electric battery, fluorescent interior lighting and under chair thermoelectric cooler.
the Eurovan Camper, the lengthy wheelbase commercial van transformed by Winnebago Industries to incorporate a pop-top roofing, two two-person beds, seating for four (plus optional solitary or two-person center seating), a single cubic base refrigerator that operates on propane, DC, or AC, a propane furnace, a wardrobe, cupboards, sink with chilled water and a grey water container, a two-burner propane kitchen stove, two two-person dinette tables, coach electric battery, residence lights, plus the two forward container seats designed to swivel around to handle the dinette/kitchen room. The 2000 EVC are 17 foot long (5,189 mm.)
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Volkswagen Transporter T4 Petrol and Diesel Owners Service and Repair Workshop Manual 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003
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